Abstract No.:	6311
Title:	Microstructural characterisation of high velocity oxy-fuel sprayed Ni particles on an aluminum 6061 substrate
Authors:	Musharaf Abbas* / University of New South Wales, Australia Paul Munroe / School Materials Science and Engineering, UNSW, Australia Gregory Smith/ Department of Materials Science and Engineering, Stony Brook University, USA
Abstract:	Nickel powder was sprayed onto an aluminum 6061 substrate using high-velocity oxy-fuel deposition. Single splats were analysed to understand splat formation behaviour, with a particular focus on splat-substrate interface properties. The microstructural features of the splats were investigated through a range of techniques including scanning electron microscopy (SEM), focused ion beam (FIB) microscopy, transmission electron microscopy (TEM), together with the scanning transmission electron microscopy (STEM) and energy-dispersive X-ray spectroscopy (EDX). The splat morphologies, their frequency of occurrence, splat cross-sectional structure and the nature of the splat-substrate interface including melting of the substrate in the thermal and kinetic energy regime of the process under consideration, were analysed. It was observed that the majority of the particles had rebounded on impact, while remnant splats that adhered to the substrate had bonded to the substrate by both the mechanical and the metallurgical bonding. Splat-substrate interdiffusion profiles, determined by STEM-EDX linescans, revealed significant interdiffusion across this interface, indicating the formation of metallurgical bonds between the Ni splats and the aluminum substrate.

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